Yamaha FZS6W 07 User Manual
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THROTTLE BODIES 7-6 EAS26980 CHECKING THE INJECTORS 1. Check: InjectorsDamage → Replace. EAS26990 CHECKING THE THROTTLE BODIES 1. Check: Throttle bodiesCracks/damage → Replace the throttle bodies as a set. 2. Check: Fuel passages Obstructions → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the throttle bodies in a petroleum- based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages with com- pressed air. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: Fuel pulsation damper CAUTION: ECA4S81002 Do not adjust the fuel pulsation damper. EAS4S81043 CHECKING THE FUEL PRESSURE 1. Check: Fuel pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the seat. Refer to GENERAL CHASSIS on page 4- 1. b. Disconnect the fuel hose (fuel tank to pri- mary injector fuel rail) from the primary WARNING EWA4S81015 Cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hoses. c. Connect the pressure gauge “1” and adapter “2” to the fuel hose (fuel tank to pri- mary injector fuel rail). d. Start the engine. e. Measure the fuel pressure. Faulty → Replace the fuel pump. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the th rottle position sensor, the engine idling speed should be properly adjusted. 1. Check: Throttle position sensorRefer to CHECKING THE THROTTLE POSITION SENSOR on page 8-79. 2. Adjust: Throttle position sensor angle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the throttle position sensor cou- pler to the wire harness. b. Connect the digital circuit tester to the throttle position sensor. Pressure gauge90890-03153 YU-03153 Fuel pressure adapter 90890-03176 YM-03176 Fuel pressure250 kPa (36.3 psi) (2.5 kgf/cm²)
THROTTLE BODIES 7-7 c. Measure the throttle position sensor volt-age. d. Adjust the throttle position sensor angle so that the voltage is within the specified range. e. After adjusting the th rottle position sensor angle, tighten the throttle position sensor screws. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Positive tester probe Ye l l o w “ 1 ” Negative tester probe Black/Blue “2” Digital circuit tester90890-03174 Model 88 maltimeter with tachometer YU-A1927 Output voltage (at idle)Adjusted by tachometer
AIR INDUCTION SYSTEM 7-9 EAS27040 AIR INDUCTION SYSTEM
AIR INDUCTION SYSTEM 7-10 1. Air cut-off valve 2. Reed valve 3. To air filter case A. To cylinder #1 and #2 B. To cylinder #3 and #4
AIR INDUCTION SYSTEM 7-11 Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1. Left front cowling inner panel (with cowling) Refer to GENERAL CHASSIS on page 4-1. Right front cowling inner panel (with cowlin g) Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. Battery Refer to GENERAL CHASSIS on page 4-1. Air filter case Refer to GENERAL CHASSIS on page 4-1. Battery box and battery box bracket Refer to GENERAL CHASSIS on page 4-1. 1 Air cut-off valve hose 1 1 Disconnect. 2 Air cut-off valve hose 2 1 Disconnect. 3 Air cut-off valve hose 3 1 Disconnect. 4 Air cut-off valve 1 5 Reed valve cap 2 6 Reed valve assembly 2 7Plate 4 For installation, reverse the removal proce- dure.
AIR INDUCTION SYSTEM 7-12 EAS27060 CHECKING THE AIR INDUCTION SYSTEM Air injection The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is neg- ative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700°C. Air cut-off valve The air cut-off valve is controlled by the signals from the ECU in accordance with the combus- tion conditions. Ordinarily, the air cut-off valve opens to allow the air to flow during idle and closes to cut-off the flow when the vehicle is being driven. However, if the coolant tempera- ture is below the specified value, the air cut-off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value. 1. Check: HosesLoose connections → Connect properly. Cracks/damage → Replace. Pipes Cracks/damage → Replace. 2. Check: Reed valve “1” Reed valve stopper Reed valve seatCracks/damage → Replace the reed valve. 3. Measure: Reed valve bending limit “a”Out of specification → Replace the reed valve. 4. Check: Air cut-off valveCracks/damage → Replace. 5. Check Air induction system solenoidRefer to CHECKING THE AIR INDUC- TION SYSTEM SOLENOID on page 8-81. EAS27070 INSTALLING THE AIR INDUCTION SYSTEM 1. Install:Plate Reed valves 2. Install: Reed valve cover A. From the air filter case B. To the reed valve Reed valve bending limit 0.4 mm (0.016 in)
8 ELECTRICAL SYSTEM IGNITION SYSTEM....................................................................................... 8-1 CIRCUIT DIAGRAM............. ................................................................... 8-1 TROUBLESHOOTING ............................................................................ 8-3 ELECTRIC STARTING SYSTEM .................................................................. 8-5 CIRCUIT DIAGRAM............. ................................................................... 8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......................... 8-7 TROUBLESHOOTING ............................................................................ 8-8 CHARGING SYSTEM ................................................................................. 8-11 CIRCUIT DIAGRAM............. ................................................................. 8-11 TROUBLESHOOTING .......................................................................... 8-13 LIGHTING SYSTEM ................................................................................... 8-15 CIRCUIT DIAGRAM............. ................................................................. 8-15 TROUBLESHOOTING .......................................................................... 8-17 SIGNALING SYSTEM ................................................................................. 8-19 CIRCUIT DIAGRAM............. ................................................................. 8-19 TROUBLESHOOTING .......................................................................... 8-21 COOLING SYSTEM .................................................................................... 8-27 CIRCUIT DIAGRAM............. ................................................................. 8-27 TROUBLESHOOTING .......................................................................... 8-29 FUEL INJECTION SYSTEM ....................................................................... 8-31 CIRCUIT DIAGRAM............. ................................................................. 8-31 ECU SELF-DIAGNOSTIC FUNCTION ................................................. 8-33 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) ..................................................................... 8-34 TROUBLESHOOTING METHOD ......................................................... 8-36 DIAGNOSTIC MODE ............................................................................ 8-37 TROUBLESHOOTING DETAILS .......................................................... 8-43 FUEL PUMP SYSTEM ................................................................................ 8-55 CIRCUIT DIAGRAM............. ................................................................. 8-55 TROUBLESHOOTING .......................................................................... 8-57 ELECTRICAL COMPONENTS ................................................................... 8-59 CHECKING THE SWITCHES............................................................... 8-63 CHECKING THE BULBS AND BULB SOCKETS ................................. 8-66 CHECKING THE LEDS ........................................................................ 8-67 CHECKING THE FUSES...................................................................... 8-67 CHECKING AND CHARGING THE BATTERY ..................................... 8-68 CHECKING THE RELAYS .................................................................... 8-71 CHECKING THE TURN SIGNAL/HAZARD RELAY ............................. 8-72
CHECKING THE RELAY UNIT (DIODE) .............................................. 8-72 CHECKING THE SPARK PLUG CAPS ................................................ 8-73 CHECKING THE IGNITION COILS ...................................................... 8-74 CHECKING THE CRANKSHAFT POSITION SENSOR ....................... 8-75 CHECKING THE LEAN ANGLE SENSOR ........................................... 8-75 CHECKING THE STARTOR MOTOR OPERATION ............................. 8-75 CHECKING THE STATOR COIL ........................................................... 8-76 CHECKING THE RECTIFIER/REGULATOR ........................................ 8-76 CHECKING THE HORN ....................................................................... 8-77 CHECKING THE ENGINE OIL LEVEL GAUGE ................................... 8-77 CHECKING THE FUEL SENDER ........................................................ 8-78 CHECKING THE SPEED SENSOR ..................................................... 8-78 CHECKING THE RADIATOR FAN MOTOR.......................................... 8-79 CHECKING THE COOLANT TEMPERATURE SENSOR .................... 8-79 CHECKING THE THROTTLE POSITION SENSOR............................. 8-79 CHECKING THE FUEL PUMP ............................................................. 8-80 CHECKING THE AIR INDUCTION SYSTEM SOLENOID ................... 8-81 CHECKING THE INTAKE AIR PR ESSURE SENSOR ......................... 8-81 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .................. 8-81